1. EXECUTIVE SUMMARY
0.1 REFRIGERATION COMPRESSOR
Refrigeration compressor is the heart of any refrigeration system. The
compressor can be: reciprocating, rotary, centrifugal, screw or an axial flow
type, based on the principle of compression. Depending upon the location of
the drive, compressors are classified as hermetic, semi-hermetic and open
type. Reciprocating and rotary compressors, which have the compressing
element and drive motor sealed in a single, welded-housing, are called
hermetically sealed compressors. Instead of single, welded-housing, if the
enclosure is bolted together, then the assembly becomes semi-hermetic. In
this type, in addition to reciprocating and rotary types, screw and centrifugal
compressors are also manufactured. However, if the compressors and drive
units are not in single housing, the compressors are called open type.
Compressors manufactured in India are mostly the reciprocating type.
Centrifugal compressors are characterised by large capacity, suitable for
extremely low temperatures and ability to carry varying loads. Rotary
compressor is a hermetic type compressor where the mechanical structure
and motor assembly are directly fitted in the same shell, and where the shell
is sealed by means of welding. Rolling piston and sliding vane are the main
types of rotary compressors. In reciprocating compressors, a connecting rod
is used to convert the rotary movement of the crankshaft to the reciprocating
movement of the piston. The piston slides, in a cylinder to compress the
refrigerant gas. When the difference between condensing temperature and
evaporating temperature is high, the pressure ratio for compression also
becomes high and conducting compression in two stages becomes desirable.
A screw compressor is a positive displacement rotary machine. Depending
upon mountings, there are two types viz. vertical and horizontal screw
compressors. Depending upon the number of screws, there are mono- screw
and twin-screw compressors.
Application of refrigeration compressors can be: for refrigerators,
deep-freezers, water coolers, bottle coolers, room air-conditioners,
packaged air-conditioners, water chillers, self-contained A/Cs,
bus/train/ship air-conditioning, refrigerated vans and cold-storages.
End-uses of refrigeration compressors can be in: domestic, commercial and
industrial sectors. In domestic sectors, the end- uses are for preserving and
storing food and for comfort air-conditioning. In the commercial sector, the
end-uses are: in central air-conditioning, water coolers, and commercial
refrigerators. End-uses in the industrial sector include preservation of food,
fruit juice concentrates, alcoholic drinks; preserving systems for meat, fish,
(iii)
2. poultry and dairy products. Other applications of refrigeration compressors
are process refrigeration such as in the drugs and pharmaceutical industry;
textile industry, rubber industry and thermal power generation.
0.2. HISTORICAL DEVELOPMENT OF COMPRESSORS
For refrigeration compressors, development of technology started around
the year 1865. In the period 1865 to 1875, a few types of refrigeration
compressors were made each year. These were massive steam-engine driven
machines with their weights in tons, considerably in excess of their capacity
in tons of refrigeration. Before 1900, some compressors were equipped with
cylinder by-pass valves for capacity control. Electric motor belted-drives
also started to make their appearance. Rare use of sulphur dioxide as
refrigerant was made. In the period from 1900 to 1925, rotating seals were
tried in small compressors. Automatic capacity controls were developed.
Operating speed increased to 800 rpm. Compressors came to be directly
driven by synchronous motors. During the period 1925 to 1950, reed valves
began to appear. The 2-pole electric motors at 3500 rpm were used for drive.
Freon refrigerants such as R-ll, R-114, and R-22 were invented. During the
period 1950 to 1975, the refrigerant R-22 was used in place of R-12 and
2-pole motors in place of 4-pole motors were used.
The ozone depleting effects of chlorofluorocarbons (CFCs) have resulted in
a large number of countries signing the Montreal Convention, according to
which the developed countries have to phase out use of R-ll, R-12, R-113,
R-114, R-115, R-13, R - l l l , R-112, R- 211, R-212, R-213, R-214, R-215,
R-216 and R-217 by the year 2000, and developing countries by the year
2015., The use of new CFCs which are ozone friendly and are under
development at present necessitate modifications in compressor designs in
some cases. They may also affect the energy efficiency of compressors also.
As regards the compressor typewise development; the reciprocating
compressors were the pioneers, followed by, centrifugal, rotary and screw
compressors. Among these types, the reciprocating compressors have almost
reached their technological development limits. Regarding the future trend,
scroll and eccentric cam compressors are being developed in advanced
countries.
0.3. STRUCTURE OF THE REFRIGERATION COMPRESSOR INDUSTRY
a) Manufacturers
The manufacture of the refrigeration compressors started in India
around the year 1960 for small hermetic compressors for
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3. refrigerators as well as the larger capacity open type compressors.
Today, a wide variety of compressors are produced in India with
the capacity as high as 700 HP. The industry is composed of both
organized sector of medium and large-scale manufacturers and an
unorganized sector of small-scale units. The small units produce
slow-speed compressor models, which are still used in India for
limited purposes.
There are 14 manufacturers in the organized sector. They are:
i) Sanden Vikas (India) Ltd., Faridabad (Haryana) - A/C
compressor for motor cars.
ii) Kirloskar Brothers Ltd., Karad (Maharashtra) - Hermetic
compressors.
iii) Shriram Refrigeration Industries Ltd., Hyderabad (A.P.) -
Hermetic compressors.
jy) DDdre) & BDywMSg, CP, Private Ltd v Bombay - Hermetic
compressors.
v) Kelvinator of India Ltd., Faridabad (Haryana) - Hermetic
compressors.
vi) Hyderabad Allwyn Ltd., Hyderabad (A.P.) - Hermetic
compressors.
vii) Voltas Ltd., Bombay & Warora (Maharashtra) - Hermetic,
Semi- hermetic and Open type compressors.
viii) Kirloskar Pneumatic Co. Ltd., Pune (Maharashtra) - Open
type compressors.
ix) Vulcan Laval Ltd., Satara (Maharashtra) - Open type
compressors.
x) Frick India Ltd., Faridabad (Haryana) - Open type
compressors.
xi) Air Control & Chemical Engineering Co. Ltd., Nandej
(Gujarat) - Open type compressors.
xii) Utility Engineers (India) Ltd., Dharuhera (Haryana) - Open
type and Semi-hermetic compressors.
xiii) Blue Star Ltd., Bombay (Maharashtra) - Open type
compressors.
(v)
4. xiv) Batliboi & Co., Udhna (Gujarat) Semi-hermetic
compressors.
b) Installed capacity and its utilisation
At present, the total licensed capacity of these companies is
13,87,250 Nos. per annum, whereas the total installed capacity is
10,22,170 Nos. As regards the utilisation of installed capacity, the
industry presents an unbalanced picture for different types of
compressors as shown in the following table.
Utilisation of capacity
(in numbers)
Compressor type Total Total Capacity
Production Installed utilisation
(1985-86) capacity
(1985-86)
Air-conditioning 10,000 25,000 40%
compressors for
automobile
Hermetic 7,78,614 8,81,000 88.4%
compressors
Open type and 2,444 15,440 15.8%
Semi hermetic
compressors
(all varieties)
c) Demand and supply forecast
Depending on the type of compressor, there are different segments
of the market. For fractional horse power and below 5 HP
compressors, the end-products are : auto air-conditioner,
refrigerators, water coolers, room type air-conditioners, bottle
coolers, deep-freezers, etc. For higher capacity compressors the
end-uses are air-conditioning and refrigeration in a variety of
industries like food preservation and processing; dairy, fish,
poultry, meat industry, pharmaceutical and chemical industry,
electronics, fertilizer, textile industries and commercial
establishments like offices, telephone exchanges, computer
(vi)
5. installations, theatres and hotels. The future demand for these
different segments is as follows:
Future demand of compressors
(In numbers)
Compressors type 1990-91 1994-95
Car A/C compressors 35,340 59,690
Hermetic compressors 15,17,605 26,96,430
Open type compressors 3,428 4,493
If the future demand is compared against the current and potential
installed capacity, the following picture emerges:-
Demand - Supply position in 1994-95
(In numbers)
Compressor type Demand Installed Capacity
capacity surplus!
shortage
Car A/C 59,690 1,00,000 +40,310
compressors
Hermetic 26,96,430 13,46,000 -13,50,430
compressors
Open type 4,493 15,890 +11,397
compressors
The table shows that additional capacity will be needed to the
extent of nearly 1.4 million numbers for hermetic compressors. In
terms of value, the total demand at present is approximately Rs.
950 million for hermetic compressors and Rs. 200 million for open
type compressors.
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6. d) Import and export
Refrigeration compressors are imported in India as part of initial
import in the phased production programme under the collaboration
agreements or some special types or capacities, which are not
manufactured in the country. Some compressors are also imported
as part of projects awarded to foreign companies.
Export of compressors is usually as a part of an end-project or a
part of an air-conditioning or refrigeration project. The export
performance of the industry is not very encouraging.
The main reasons for this are:
Price The international prices are at least 40% cheaper than
thejndian export prices.
Quality The quality of products of advanced countries is
superior and more reliable.
Models The advanced countries do continuous product
improvement and are able to bring new models every
year in the market.
Marketing The marketing and after sale service are not properly
undertaken by the Indian manufacturers, barring a few
exceptions. The Indian manufacturers will have to
improve on all these disadvantages with appropriate
help from the Government.
e) Financial status and scale of operation:
Most manufacturers are multi-product companies producing
compressors as one of their products: hence the data of separate
investment and costs for compressors vis-a-vis income is not
available. The financial health of a company as a whole has,
therefore, been studied. It was observed that all companies, except
ACCEL, are making profit. ACCEL had been making losses for
some years and it has been taken over by Best & Crompton Ltd.,
since 1986 and is under rehabilitation. Amongst the companies,
Frick India Ltd., Vulcan Laval Ltd., Blue Star Ltd., and Kelvinator
of India show sound financial health with the return on capital
employed is consistently above 10% and return on share capital
above 35%.
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7. 0.4. TECHNOLOGICAL STATUS OF INDIAN INDUSTRY
a) Sources of technology
Since the beginning of the refrigeration industry in India,
refrigeration compressors have been manufactured with foreign
technical collaboration. Even today, most of the established
manufacturers continue to enter into fresh foreign collaborations
for producing new types of compressors or for updating and
expanding the present range. The only notable exception in this
regard is Godrej & Boyce Mfg. Co. Ltd. which has developed a
hermetic compressor for its refrigerator entirely with its own
research and development. The details of foreign collaborations of
the Indian manufacturers are shown in the following table.
FOREIGN COLLABORATIONS
Manufacturer Collaborator Year Type of compressor
1. Sanden Vikas * Sanden Corporation 1983 Open type reciprocating
(India) Ltd. (Japan) compressor with clutch
for motor car air-
conditioner
2. Kirloskar Tecumseh Products 1963 Hermetic compressors
Brothers Ltd. Co. Inc. (U.S.A.) (1/8 HP-5 HP)
3. Shriram Refriger- Westinghouse Indus- 1961 Hermtic
ration Industries tries Corpn. (U.S.A.) compressors
Ltd. (1/8 to 2 1/2 HP)
Lee Refrigeration 1979 -do-
Corpn. (U.S.A.)
Daikin Industries 1981 Rotary hermetic
Ltd. (Japan)
* Tecumseh Co. 1987 Hermetic compressors
(U.S.A.) (1/8 to 7 1/2 HP)
4. Kelvinator Kelvinator 1960 Hermetic 1/8 & 1/6 HP
of India Ltd. International Corpn. reciprocating
(White Consolidated
Industries, U.S.A.)
* -do- 1987 Hermetic reciprocating
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8. Manufacturer Collaborator Year Type of compressor
5. Hyderabad Allwyn Prestcold Ltd. (U.K.) 1957 Slow speed hermetic
Ltd. Hermetic (FHP)
* Hitachi Ltd. (Japan) 1981 High speed Hermetic
(1/8 & 1/6 HP)
6. Voltas Ltd. Carrier Corpn. 1963 Open type reciprocating
(U.S.A.) &1972(18TRto 120 TR)
* Danfoss A/S 1984 Hermetic reciprocating
(Denmark) (1/8 to 1/6 HP)
* Carrier Corpn. 1983 Semi- hermetic recipro-
(U.S.A.) cating (7 - 14 TR)
* Danfoss A/S 1987 Product of refrigeration
(Denmark) compressors
7. Kirloskar Grasso Products 1961 Open type ( 1 0 - 200 TR)
Pneumatic Co. Ltd. B.V. Holland 1965 Recip.
-do- 1973 Semi-hermetic
*-do- 1985 (45 - 180 TR)
Westinghouse Elec. 1962 Semi-hermetic
Intl.Co. (U.S.A.) (5 TR & 7 TR)
Hitachi Ltd. 1969 Centrifugal
(Japan) (200 TR & 600 TR)
Sutrak 1973 Open type reciprocating
(West Germany) (7 to 15 TR)
* Howden Compressors 1988 Screw compressors
Ltd. (U.K.) (20 - 200 TR)
8. Frick India Ltd. Frick Waynesboro 1962 Open type reciprocating
Inc. (U.S.A.) &197915-200TR)
Fedders Corpn. Screw compressors
(U.S.A.) (1100-300 TR)
Centrifugal (300-600 HP)
9. Utility * The Trane Co. 1983 Open type reciprocating
Engineers (I) Ltd. U.S.A. (10 to 80 TR) Hermetic
(5 TR & 7.5 TR)
Hermetically sealed
centrifugal
(100-800 TR)
10. Vulcan Laval * Star Refrigeration 1982 Open type
Ltd. AB (Sweden) reciprocating
(6.5 TR - 230 TR)
* -do- 1984 Screw type
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9. Manufacturer Collaborator Year Type of compressor
11. Blue Star * Borg Warner Air- 1983 Centrifugal
Ltd. conditioning Inc. (150-700 TR)
(U.S.A.)
12. Batliboi * Daikin Industries 1984 Semi-hermetic
&Co. Ltd.(Japan) compressors
(10TR-50TR)
13. Air Control Sabroe & Co. 1965 Open type
& Chemical (Denmark) reciprocating
Engg. Co. Ltd. (5.6 - 70.4 TR)
(ACCEL)
14. Gujarat Ind. Inv. * Dressar Industries 1984 Refrigeration
Co. Ltd., Inc. (U.S.A.) compressors
15. Shiv Shakti Engg. Rotocold Ltd. 1989 Rotary compressors
Co. Pvt. Ltd. (U.K.)
16. Pradeep Kumar Industrie Riuuite 1985 Sealed compressors
New Delhi Eurodomostical SPA
(Italy)
Note: Collaborations, still current, are indicated by an * (asterisk)
There is no example of technology transfer among Indian
manufacturers. Moreover, collaborations with the same foreign
companies have been concluded at different times for updating or
manufacturing new types of compressors. All this goes to show that
there is hardly any original design and development work
undertaken in India; or, whatever has been attempted so far has not
met with much success. The R&D effort in India is mainly aimed at
indigenisation of the compressors as per the collaborator's
specifications and according to the phased manufacturing
programme.
b) Selection of foreign collaborator
The selection of foreign collaborator was found to be based on
many factors such as:
i) Quality of products
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10. ii) Financial participation of collaborator
iii) Willingness of collaborator
iv) Previous trading relations i.e. the Indian company
importing the collaborator's compressor for use in own
products or projects
v) Availability of collaborator for collaboration in India.
There are three companies, namely, Sanden Vikas (India) Ltd.,
Kelvinator of India Ltd. and Frick India Ltd., in which there is a
financial participation of the collaborator in addition to technical
collaboration.
c) Restrictive clauses in collaboration agreements
The restrictive clauses pertain to export, use of collaborator's
brand name and transfer of technology to other Indian
manufacturers. Regarding exports, most collaborators have barred
the Indian manufacturers to export to countries where the
collaborators have their own licensing arrangements or trade
interests.
Regarding the use of collaborator's brand-name, in most cases the
words "manufactured under license of." etc., can be used during the
period of agreement.
The transfer of technology has not been allowed during the tenure
of agreement in the case of any company. After the tenure is over,
the Indian company is free to transfer technology to others.
d) Technical support of collaborator
In all the collaborations, the collaborator has agreed to give all
technical support for indigenisation of the compressor. Adequate
training in collaborator's plant as well as in Indian company's plant
is provided.
e) Research and development activities
The research and development carried out by the Indian
manufacturers is of applied nature. The main effort is to indigenise
the collaborator's design within the agreement period. Once this is
(xii)
11. achieved, many manufacturers have done development in
compressor components by way of change of material, little
modification in design and such other improvements. Some have
developed compressor models of intermediate capacities in the
range by making suitable dimensional changes. No manufacturer
has designed a compressor on his own except Godrej & Boyce. The
reasons for this state of affairs are :
i) The low volume of turnover of business does not permit
sizeable investment in original research.
ii) It is faster to update technology through collaboration than
through own research.
f) R&D organization and expenditure
Most compressor manufacturing companies in India are
multi-product companies, manufacturing allied refrigeration
products or components or other engineering products not
connected with refrigeration. The research and development
activities are, therefore, commonly undertaken in a central R&D
establishment. Separate R&D organization and expenditure on
compressor development were therefore not available in most
cases.
The following table shows the annual R&D expenditure of the
companies.
R&D Expenditure
(Rs. in million)
Company Expenditure (Year)
Shriram Refrigeration Industries 2.3 (1985-86)
Kelvinator of India Ltd. 11.89 (1987-83)
VoltasLtd. 21.7(1987-88)
Vulcan Laval Ltd. 6.0 (1985-86)
Kirloskar Pneumatic Co. Ltd. 6.3 (1986-87)
Hyderabad Allwyn Co. Ltd. 17.0 (1987-88)
Kirloskar Brother Ltd. 11.2 (1988-89)
Godrej and Boyce 17.2 (1987-88)
(xiii)
12. The other companies like Sanden Vikas (India), Utility Engineers,
Batliboi & Co. and Blue Star Ltd. are getting all R&D support from
their collaborators. Frick India Ltd. will soon have its own R&D
centre which is at present under construction.
0.5. INTERNATIONAL STATE-OF-THE-ART SCENE
To understand the international state-of-the-art, 26 major manufacturers
were contacted on the basis of their collaborations, in India, import of
compressors, into India and also on the basis of reputation. In response,
product literature from some, like GRASSO, HITACHI, HOWDEN,
MITSUBISHI, COPELAND and LINDE was received. Few copies of
product literature of STAL and DAIKIN were also received from their
Indian collaborators. Apart from this, the Japan Refrigeration and
Air-conditioning Industries Association and American Society of Heating,
Refrigeration and Air-conditioning Engineers Inc. were also contacted.
Publications of Purdue University, U.S.A., on Compressor Engineering were
also referred to.
a) Manufacturers
GRASSO PRODUCTS
This is an internationally independent, operating company in the
field of refrigeration, air-conditioning and stop valves for the last
125 years. Businesswise, the company's net sales were in 1984 -
69,503,000 Dutch Guilders, in 1985 - 63,928,000 Dutch Guilders;
and in 1986 - 135,987,000 Dutch Guilders. Expenditure for R&D in
1985 amounted to 3.5% of net sales.
COPELAND CORPORATION
This is an American, refrigeration compressor manufacturing group
of companies, building accessible hermetic compressors since
1957. The range includes 50 W to 540 W compressors. It is the
largest manufacturer of compressors in terms of monetary value. Its
products are mainly in range of 2 HP and 4 HP.
LINDE REFRIGERATION LTD.
For over 100 years, this company has developed and manufactured
a range of refrigeration equipment. Linde manufactures open type,
screw and reciprocating compressors.
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13. HOWDEN COMPRESSORS LTD.
This company (founded over 125 years ago) was the first in the
world to commercially produce screw compressors for refrigeration
purposes. Howden manufactures compressors with capacities in the
range of 340 m /hr to 1200 m3/hr.
MITSUBISHI HEAVY INDUSTRIES LTD.
This is a Tokyo based company, established 45 years ago.
Mitsubishi manufactures : hermetically sealed rotary and
reciprocating compressors, semi-sealed reciprocating compressors
and open type screw compressors.
MANEUROP
It is well known French manufacturer upto 12 hp. capacity
compressors.
CARRIER, TRANE, YORK AND SNYDER
They are large U.S. based manufacturers of reciprocating and
centrifugal compressors both of open and semi-hermetic designs.
FRICK AND DUNHAM - BUSH
They are large manufacturers of screw compressors in U.S.A.
b) Latest developments at International level
i) Semi-hermetic reciprocating compressor
Improvement in part-load efficiency of semi-hermetic
reciprocating compressor has been developed by using
block suction unloading by Borg Warner Air-conditioning
Inc. (York) U.S.A.
Copeland Corporation, Sydney, has developed, a new
valves system. This valve is made from a high temperature
polymeric material, together with a laminated steel valve
plate and ring type suction valve. It provides large flow
areas, low clearance volumes and high efficiency.
Discharge valves are of polymide resin. With this valve
(xv)
14. system, the company claims that EER has increased by 16%
and compressor capacity by 25%.
ii) Hermetic Reciprocating Compressor
A unit that encloses a motor compressor and a condenser of
refrigerant fluid in a single hermetic casing has been tested
by NECCHI SPA, PAVIA, ITALY.
iii) Compressor Valves
Material for compressor valves has been recently selected
and tested. The best material for this use is the Martensetic
Stainless Steels with preference for UHBSS-716.
iv) The Eccentric Cam Compressor
This new product has been tried by Copeland. The eccentric
cam compressor fulfills the required need for a low-cost,
high efficiency and durable air-conditioning for 1.5 to 2 ton
capacity range.
v) Single Screw Oil Flooded Refrigerant Compressor
This is a rotary positive displacement compressor. The
compressor gets its name from the single screw rotor that
meshes with 2 sealing rotors called star rotors or gate
rotors. The advantages of single screw compressors are
compactness, versatility, reliability, maintainability, less
weight, less noise and vibration as compared to existing
reciprocating units.
Rotary and Screw Compressors are not developed or
manufactured in India. Hermetic Rotary Compressors arc
not suitable for Indian conditions where repairs are mostly
done in the small service shops, which are, often, ill
equipped. Special precautions required during
manufacturing, installation, and use of rotary compressor
are not observed in India. Further, in India, low evaporating
temperature applications are more popular in the
refrigeration field where the use of rotary compressors is
unsafe and unavoidable. With the present taxes and general
economic conditions in India, a tendency to repair
compressors and re-use them is more common, and rotary
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15. compressors are most unsuitable from this point of view as
they cannot be easily repaired but are replaced with new
ones in advanced countries.
Screw compressor is a positive displacement rotary
machine combining the characteristics and suitability of a
reciprocating unit with the compactness and smooth
running of a rotary compressor. Hence, this should become
a new thrust area in India. Recent trends at international
level indicate development and extensive
commercialization of screw compressors by leading
companies. Horizontal and Vertical screw compressors are
manufactured by STAL Refrigeration in the range of 245
m /hr to 4700 m /hr. Hitachi has developed horizontal
semi-hermetic screw compressors in the range of 137 m /hr
to 209 m /hr. Mitsubishi has developed a tiny screw
compressor for Bus A/c with 9 m /hr capacity. Howden
manufacturers screw compressors in the range of 340 m /hr.
to 12000 m3/hr.
vi) Refrigerants
Refrigerants are a medium of heat transfer in a refrigerating
system which pick up heat by evaporating at low
temperature and give up heat by condensing at high
temperatures and pressure. Upto 1985, only R-ll, R-12,
R-22, and NH3 were the manufactured and available
refrigerants in India. High pressure refrigerants R-13,
R-502, R-503 were imported. As on today, refrigerants like
: R-13 Bl, R-13, R-500 and R-114, which are used at an
international level are not available indigenously.
The chlorofluorocarbon refrigerants, have been, at centre of
environmental controversy because of their Ozone
depleting properties. As per the Montreal Convention, the
existing CFC's, R-ll, R-12, R- 113, R-114, R-115, R-13,
R - l l l , R-112, R-211, R-212, R-213, R-214, R-215, R-216
and R-217 are to be phased out in developed countries by
the year 2000 and in developing countries by the year 2010.
R-22 has not been included in the list due to be phased out.
New substitute which are emerging, are R-123, R-1416 and
R-134, but they are yet to complete long term toxilogical
trials. Developing countries have to phase them out by year
2015. Use of new Refrigerant will entail change in
compressor designs.
(xvii)